A/S Reg. No. 17 12 31 Telephone: 45 74 12 36 36 Telefax: 45 74 43 36 46 Telex: 5 23 18 Bank: Den Danske Bank, No. 32 27 A’GRAMKOW A/S Augustenborg Landevej 19 DK-6400 Sønderborg Denmark INSTRUCTIONS RHS 700 Recovery, Recycling, Evacuation and Charging Station RHS 700 C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 0.1 - Contents RHS 700 1. Application 2. Safety precautions 3. Components 4. Before use 5. Test 6. Recovery/recycling 7. Evacuation 8. Charging 9. Maintenance 10. Trouble shooting 11. Service set 12. Accessories/spare parts 13. Specifications 14. Pos. no. location 15. Appendix C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 1.1 - Application Your new RHS 700 station represents the latest in equipment for servicing airconditioning units (A/C units). The station is designed for refrigerants R12 and R134a. It can, and must, only be used for one of these refrigerants. RHS 700 is a test, recovery/recycling-(draining/cleaning), evacuation, oil/refrigerant charging station and is thus able to perform a total process cycle in servicing A/C units for the automobile industry.
- 1.2 - Application We reserve the right to make constructional and design changes and accept no responsibility for printing errors. RHS 700 complies with European standards on “Safety and health” and is GStested. See appendixes, "Declaration of Conformity" and TÜV test report. C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 2.1 - Safety precautions 1. Always wear protective goggles and gloves when working with refrigerant. 2. Do not allow refrigerant to come into contact with the skin or eyes. 3. Before disconnecting RHS 700 from the A/C unit, make sure that the process is completed so that refrigerant does not escape to the atmosphere. 4. RHS 700 is for use only in dry indoor surroundings. 5. Disconnect the electrical supply before performing maintenance on RHS 700. 6.
- 3.1 - Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Main switch Operation time indicator Low-pressure valve Pressure gauge - low pressure High-pressure valve Pressure gauge - high pressure Charging switch Charging quantity indicator Evacuation switch Cylinder full - lamp Vacuum check Recovery/recycling switch Vacuum gauge C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 3.2 - Components 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. High-pressure side Oil beaker - 250 ml High-pressure hose - red Oil charging Sightglass Low-pressure side Low-pressure hose - blue Service coupling - high pressure Service coupling - low pressure Oil drain valve C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 4.1 - Before use Check the following: - whether the station has been damaged in transit - if so, contact supplier immediately; - oil level in vacuum pump: it must not be below the centre of the sight glass. If the level is too low, see section MAINTENANCE for vacuum oil replenishment instructions; - whether the mains supply is as stated on the station nameplate; - whether the refrigerant in the A/C unit is as stated on the station nameplate. Preparation: - Connect mains plug to mains supply.
- 4.2 - Before use Connection of service couplings C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 4.3 - Before use C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 5.1 - Test The test function must be performed to check the station. 1. Close both valves on the control panel (pos. 1-2). 2. Connect the high and low-pressure hoses to the A/C unit and open the service couplings. 3. Switch on the A/C unit and read the pressures on the high and low-pressure gauges (pos. 3/4). The correct pressures are given in the A/C unit manual. 4. Perform a condition diagnosis in accordance with the supplier’s instructions. See appendix “Example of trouble shooting in an A/C unit”.
- 6.1 - Recovery/recycling When an A/C unit is to be repaired or serviced, the RECOVERY/RECYCLING process must be used in order to drain refrigerant from the A/C unit. 1. Make sure that all valves are closed, then connect high and low-pressure hoses to the A/C unit and open the service couplings. 1. Switch on the main switch process switch and the RECOVERY/RECYCLING 2. Open valves 1 and 2. Provided there is pressure/refrigerant in the A/C unit, it will be automatically emptied by RHS 700.
- 7.1 - Evacuation After servicing the A/C unit, air and/or moisture must be evacuated. Air and/or moisture in the A/C unit will impair system operation. 1. Set the main switch on I and switch on the EVACUATION process switch (if the pressure exceeds 0.2 barg, the evacuation process cannot be started). If the pressure does exceed 0.2 barg, a short recovery process should be performed. 2. Before connecting the service couplings to the A/C unit, read the vacuum gauge. This reading is the max.
- 8.1 - Charging The required quantity of refrigerant can be seen in the vehicle manual or on the nameplate under the vehicle bonnet. 1. Close valve 1 and open valve 2 . Then connect high and low-pressure hoses, keeping both hose valves closed. (When charging R12 systems, do not connect the high-pressure hose at this point). 2. Set the main switch on I and switch on the CHARGE process switch The high-pressure hose will now contain refrigerant. 3.
- 8.2 - Charging 4. Open the high-pressure valve on the red hose (on R12 systems simply close the hose) and observe the charging quantity on the charging quantity indicator. When the black pointer has reached the red pointer, the charging process must be stopped with the process switch. 5. It is now possible to check the function of the A/C unit by closing valves 1 and 2 and opening both hose valves. 6.
- 9.1 - Maintenance 3) 5) 6) 9) 8) 18) M1) M2) M3) SP4) Suction accumulator Acid filter / filter drier Check valve Check valve Filter drier Charging cylinder Compressor Condenser Vacuum pump Pressure control C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 9.2 - Maintenance To observe the warranty on RHS 700, all components used for maintenance must be identical to those in the service set, see Section 9. To ensure problem-free operation of RHS 700, the station must be maintained in accordance with the following: The power supply to the station must be switched off. For each 25 operating hours: A large amount of the moisture evacuated from the A/C unit accumulates in the vacuum oil and therefore it can be advantageous to change the oil from time to time.
- 9.3 - Maintenance The condenser cooling surface must be kept clean: - Remove the rear panel of the station (4 screws). - Clean the cooling surface with compressed air and perhaps a soft brush. Be careful not to bend the fins since this would reduce the air flow and impair condenser capacity. - Replace rear panel. Check the oil level in the vacuum pump: - If the oil level is below the centre of the sight glass, replenish as follows: - Remove cap (pos. 32) to replenish vacuum pump.
- 10.1 - Trouble shooting Test process Problem Fault Pressure gauge shows no 1. + 2. Valve not opened pressure Remedy 1. Open high and low-pressure valves on service couplings 2. Open valves on service couplings 3. No refrigerant in A/C unit Pressure gauge shows 1. A/C unit defective the same reading all the time 2. A/C unit not cut in 3. Repair A/C unit 1. Empty A/C unit and repair 2. Cut in A/C unit Recovery process: Problem Fault Recovery process does 1.
- 10.2 - Trouble shooting Evacuation process: Problem Fault Remedy Vacuum pump does not run 1. RHS 700 not cut in 1. Cut in RHS 700 2. Overpressure in A/C unit 2. Cut in recovery process 3. Internal component fault Vacuum pump runs but 1. Service couplings not fitted correctly does not build up enough vacuum 2. A/C unit defective/leaking 3. Internal component fault 3. Contact RHS 700 supplier 1. Fit service couplings correctly 2. Repair A/C unit 3.
- 11.1 - Service set no. 645-010003A (RHS 700 unit) Quantity Description Code no. 1 Filter drier - short 069-7480069 1 Filter drier - long 069-7480077 0.25 l Compressor oil - mineral 290-0001250 0.25 l Oil for vacuum pump 290-0001272 C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 12.1 - Accessories / Spare parts Qty Description Code no.
- 13.
- 13.
- 14.1 - Pos. no. location Wiring diagram: (645-120000A-03) C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 14.2 - Pos. no.
- 14.3 - Pos. no. location Mechanical diagram (645-120001A-00) C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 14.4 - Pos. no. location 3) 5) 6) 9) 8) 18) M1) M2) M3) SP4) Suction accumulator Acid filter / filter drier Check valve Check valve Filter drier Charging cylinder Compressor Condenser Vacuum pump Pressure control C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.03.
- 15.1 - Appendixes Example of trouble shooting on an A/C unit: Conditions: 1. Ambient temperature 30-35°C (86-95°F) 2. Motor speed 2,000 rpm 3. A/C unit temperature setting Maximum Under the above conditions an intact A/C unit will show the following pressures in the TEST process: High pressure 15 bar Low pressure 2 bar Follow the TEST process as shown in section 5: - Connect service couplings to the A/C unit.
- 15.2 - Appendixes Test 1: High pressure Low pressure Fault/problem Unsatisfactory refrigeration output 8 - 9 bar Approx. 0.8 bar Symptom Virgin ventilation air Possible cause Leak in A/C unit Remedy Locate leak and repair Air bubbles in sight glass Insufficient refrigerant Replenish refrigerant in A/C unit Test 2: High pressure Low pressure Fault/problem Unsatisfactory refrigeration output Approx. 20 bar Approx. 2.5 bar Symptom C:\RHS Computer Files\Instructions\RHS\GB\645-40\0009A-01.doc 1997.
- 15.3 - Appendixes Test 3: High pressure Low pressure Fault/problem A/C unit runs irregularly Approx. 7 - 15 bar Approx. 1.5 bar Symptom Varying pressures on high and low-pressure sides Possible cause Moisture in A/C unit causes ice on expansion valve and reduces output. Filter drier saturated Remedy Empty, evacuate and recharge A/C unit. After recovery process replace filter drier. If necessary, remove and clean expansion valve. Replace valve or fit new valve.
- 15.4 - Appendixes Test 5: High pressure Low pressure Fault/problem Unacceptable cooling Approx. 19 - 20 bar Approx. 2.5 bar Symptom Ice or moisture on hoses on high and lowpressure sides of A/C unit Possible cause Expansion valve defective or sensor placed incorrectly Remedy Check position of expansion valve sensor. Expansion valve opens Replace expansion too much valve. Test 6: High pressure Low pressure Fault/problem A/C unit does not cool Approx. 7 - 10 bar Approx.
- 15.5 - Appendixes Pressure vessel declaration We confirm herewith that the condition of the pressure vessel in this unit conforms to regulations laid down by the appropriate authorities: Suction accumulator, pos. 4: Manufacturer: Denaline S.R.L. Via Segaluzza 11/B Italy Type: GRA.120.240.0 Permissible working pressure: PS = 23 bar Permissible working temperature: -40/70°C Volume: V = 2.4 litres Filter drier, pos. 5: Manufacturer: RTI Technologies Inc.
- 15.6 - Appendixes Filter drier, pos. 8: Manufacturer: RTI Technologies Inc. (A’G subsidiary) York, PA USA Type: 026-80077-00 Permissible working pressure: PS = 31.05 bar Permissible working temperature: 10/120°C Volume: V = 0.83 litres Charging cylinder, pos. 10 Manufacturer: A’GRAMKOW A/S Augustenborg Landevej 19 DK-6400 Sønderborg Denmark Type: 645-010038A Permissible working pressure: PS = 25 bar Permissible working temperature: 10/70°C Volume: V = 4.
